682.88105.00 SC1-610.8 Royal Series TCU OI Manual PDF

Operation and Installation Manual
Royal Series
Water Temperature
Control Units
Important! Read Carefully Before Attempting to Install or Operate Equipment
Part No. 682.88105.00
Revision E
Bulletin No. SC1-610.8
Write down your unit serial number(s)
________________
________________
here for future reference
________________
________________
________________
________________
________________
________________
Sterling/Sterlco is committed
to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual
are subject to change without notice.
Copyright Sterling/Sterlco 2007
All rights reserved.
Effective 8/29/07
Part No. 682.88105.00
Revision G
Bulletin No. SC1-610.8
Page 2
Royal Series Water Temperature Control Units
Safety Considerations
Sterling Royal Series temperature control units are designed to
provide safe and reliable operation when installed and operated
within design specifications, following national and local safety
codes.
To avoid possible personnel injury or equipment damage when
installing, operating, or maintaining this equipment, use good
judgment and follow these safe practices:
Only PROPERLY TRAINED personnel familiar with the
information within this manual should work on this equipment.
Follow all local SAFETY CODES.
Royal Series cabinets and piping are hot and are a BURN
HAZARD.
Do not operate a Royal Series system without all outer panels
installed. Pressurized hot water leaks can cause serious injury.
Wear SAFETY GLASSES and WORK GLOVES.
Use care when LOADING, UNLOADING, RIGGING, or
MOVING this equipment.
Operate this equipment within design specifications.
OPEN, TAG, and LOCK ALL DISCONNECTS before
working on equipment. Sterling recommends following OSHA
Lock-Out/Tag-Out Standard 29 CFR 1910.147.
Make sure the unit is properly GROUNDED before switching
power on.
When welding or brazing in or around this equipment, be sure
VENTILATION is ADEQUATE. PROTECT adjacent
materials from flame or sparks by shielding with sheet metal.
An approved FIRE EXTINGUISHER should be close at hand
and ready for use if needed.
Do not jump or bypass any electrical safety control.
Do not restore power until all tools, test equipment, etc. have
been removed and the panels replaced.
Page 3
Table of Contents
1
General Information ................................................6

1-1
1-3
1-4
1-5
Shipping Information .............................................12

2-1
2-2
2-3
2-4
2-5
2-6
Introduction ................................................................................... 33
Startup Checklist ........................................................................... 33
Starting the Temperature Control Unit .......................................... 34
Sequence of Operation ................................................................. 35
Checking Motor Rotation Direction................................................ 36
Shutting Down the Temperature Control Unit ............................... 36
Unit Maintenance....................................................38
6-1
Page 4
Identifying Mechanical Controls and Features .............................. 27

The Microprocessor Controller ...................................................... 31
Operating the Unit with the Controller ........................................... 31
Communications ........................................................................... 32
Startup and Operation ...........................................33

5-1
5-2
5-3
5-4
5-5
5-6
Installation Location Considerations.............................................. 16

Process Approach Temperature Considerations........................... 16
External Piping Sizing Considerations .......................................... 16
Piping Considerations for Permanent Installations........................ 17
Piping Considerations for High Mobility Installations..................... 18
Process Water Considerations...................................................... 18
Making Process Water Connections ............................................. 19
Making Cooling Water Connections .............................................. 20
Making System Purge Connections .............................................. 21
Making Electrical Connections ...................................................... 24
Identifying Controls and Features ........................27

4-1
4-2
4-3
4-4
Unpacking and Inspection............................................................. 12

In the Event of Shipping Damages................................................ 12
If the Shipment is Not Complete.................................................... 13
If the Shipment is Not Correct ....................................................... 13
Returns ......................................................................................... 13
Uncrating Your New Royal Series System.................................... 14
Installation ..............................................................16
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
Introduction ..................................................................................... 6
Models Covered .............................................................................. 7
Standard Royal Series Features ..................................................... 7
Available Options ............................................................................ 8
Preventive Maintenance................................................................ 38
6-2
6-3
6-4
6-5
6-6
7
I
Corrective Maintenance ................................................................ 39

Restoring the Controller to Factory Setup ..................................... 41
Electrical Connections................................................................... 41
Safety Devices .............................................................................. 42
Cleaning and Storage ................................................................... 44
Troubleshooting .....................................................45
Index........................................................................48
Page 5
1
1-1
General Information
Introduction
Sterling/Sterlco Royal Series water temperature control units are
reliable, accurate, and easy-to-use process temperature control
units. They are self-contained, portable, and shipped ready to use.
The Royal Series water temperature control unit is designed to
circulate water through your process and to precisely,
automatically, and reliably maintain it at a specified temperature.
Standard unit operating range is from 0F (-17C) to 250F
(121C), or up to 300F (149C) as an option. The unit is suited for
use with city water, water from portable or central chillers or
towers, or well water.
These units are designed for rapid recirculation of a relatively
small amount of water to provide close and uniform temperature
relation between To Process and From Process lines. This
performance, of course, depends on the configuration of your
process and any restrictions within the mold. The recirculation,
combined with the large immersion heater and cooling capability,
gives fast and accurate response to bring the water up to
temperature or to changes in the settings when needed.
The 2010 Series water temperature control unit is a self-contained
system consisting of a centrifugal pump, electric immersion heater,
cool/vent solenoid valve, and electrical control, including a PID
microprocessor controller and thermocouple. It is designed for use
in process temperature control applications using water or a
water/glycol mix. Any other use or fluid is prohibited.
Some standard safety devices include a mechanical
overtemperature safety thermostat, a pressure relief valve, motor
overload protection, a low pressure cutout switch, branch fusing,
and non-fused lockable rotary disconnect.
A properly installed, operated, and maintained Royal Series system
provides years of reliable operation. Please read and follow the
instructions in this manual to get the most satisfaction from your
Royal Series system.
Page 6
1-2
Necessary Documents
The following documents are necessary for the operation,
installation, and maintenance of Sterling/Sterlco Royal Series
water temperature control units. Additional copies are available
from Sterling.
Familiarize the appropriate personnel with these documents:
This manual.
The controller operation manual.
The electrical schematic and connection diagram placed inside
the control enclosure.
The operation and installation manuals for accessories and
options selected by the customer.
The Customer Parts List included in the information packet.
1-3
Models Covered
This manual provides operation, installation, and maintenance
instructions for the Royal Series water temperature control unit.
Model numbers are listed on the serial tag. A model number
followed by Q indicates a specially constructed unit, and not all
information in this manual may apply. Make sure that you know
the model number, serial number, and operating voltage of your
temperature control unit if you contact Sterling.
1-4
Standard Royal Series Features
Compact, rugged cabinet with easy-access side panels
Cast-and-flange design to reduce connection points
Half- and full-heat automatic switching capability
Dual stage Incoloy immersion heater with IEC contactors
NEMA 12 electrical enclosure
Microprocessor controller with fuzzy logic; includes

diagnostics features with indicator and warning status lights;
CE and CUL
Page 7
1-5
Forward-facing liquid-filled To and From Process pressure

gauges
Independent high temperature safety thermostat
Non-fused lockable rotary disconnect
Branch fusing
cooling solenoid valve on to 3 hp (0.56 to 2.24 kW)

models; slow-close cooling solenoid valve on 5, 7, & 10
hp (3.73, 5.60, & 7.46 kW) models
EPDM/NI-Resist pump seal
Adjustable low supply water pressure switch; factory-set at

16 psig (110 kPa/1.1 bars)
150 psig (1,034 kPa/10.3 bars) pressure relief valve
Choice of 230 or 460 operating voltages
water supply and drain connections; 1 process

connections
Automatic vent sequence
3 (76 mm) casters
Operating range of 0F to 250F (-17C to 121C)
Available Options
Royal Series systems are available with options to tailor the unit to
your requirements. Some are factory installed; some can be retrofitted in the field. Consult your Sterling sales representative for
more information. Available Royal Series options include:
Controller with integral flow meter; with:

Up to 30 gpm (114 lpm) flow indicator
- or 30 to 75 gpm (114 to 284 lpm) flow indicator
0-20 mA and 4-20 mA current control output
Page 8
Remote set point and retransmission; 0-20 mA and 4-20

mA
RS-232 or RS-485 communications
Remote sensor; 10 ft. (3 m)
Remote controller enclosure
Heaters available in 12 kW, 18 kW, 24 kW, 36 kW, and 48

kW on direct-injection compact models; 36 kW and 48 kW
heaters available on direct-injection upright models
Closed-loop heat exchanger available in 3.7 sq. ft. (0.344 sq.

m) on compact models; 3.7, 7.4, 11.2, 18.1, and 27.0 sq. ft.
(0.135, 0.688, 1.042, 1.683, and 2.511 sq. m) on upright
models
Quick Cool function
Auto system water purge (mold purge)
Y-strainer
Hammer arrestor (water hammer shock stop)
Remote start/stop control
Rubber feet; available in lieu of casters
Non-ferrous brass construction
Slow-close cooling solenoid valves available in 1/2 x 9/16

(CV = 3.5) and 3/4 x 3/4 (CV = 5.5)
Modulating valves available in 1/2 (CV = 0.4, 1.3, 2.2,

or 4.4), 3/4 (CV = 5.5 or 7.5), 1 (CV = 10 or 14),
and 11/4 (CV = 20)
Two-zone stack rack with casters, common wiring and piping

available; compact units only
300F (149C) operation; includes graphite-impregnated

silicon carbide seal
Audible and visual general fault alarm
Electrical operation available in 208, 230, 460, and 575 volts,

60 Hz; 200, 380, and 415 volts, 50 Hz
UL/CUL-listed electrical subpanel
Page 9
Figure 1
Typical Royal Series Water Temperature Control Unit and Specifications
Direct Injection
FROM PROCESS
TO PROCESS
COOLING WATER OUT

COOLING WATER IN
THIS EQUI PMEN T CONTAI NS FLU ID, PIPI NG A ND CONNECTI ONS

WHI CH MAY B E EXTREMEL Y HO T AND CO ULD CAUSE SERIO US
BURNS AND P ERSONA L I NJURY.
RECO GNI TI ON O F AND COMPLI ANCE WITH TH E FO LLO WING
PRECAUTIO NS ARE THE SOL E RESPON SIBIL ITY O F THE USER
OF THIS EQUI PMENT.
1 . E QUIP MENT MUS T BE PRO PERLY GROUNDED.
2 . EL ECTRIC PO WER SUP PLY W IRIN G AND DEVICES MUST BE
PROPERL Y FUSED A ND SIZED TO MEET REQUI REMEN TS O F
THIS EQ UIPMENT, AND ALL APPL ICABLE CO DES.
3 . E LECTRI C PO WER SO URCE MUS T BE DI SCONNECTED PRIOR
TO O PENI NG A NY EL ECTRIC ENCL OSURE OR W ORKING O N
ANY ELEC TRI C CO MPONENTS.
4 . AL L CONTROL DEVICE S MUST BE MAINTAINED IN PRO PER
WO RKING CO NDITIO N TO AVOI D ACCI DENTAL OVERHEATING
OR DANGE R TO OPERA TI NG PERSONNEL .
28 3/4"
5 . THI S EQUI PMENT MUST NO T BE USED W HIL E UNATTENDED.
ES TE EQUIPO CO NTI ENE FLUI DO, TUB ERIA Y CONEXIO NES Q UE

PUED EN ESTAR PEL IGR OSAMENTE CALIENTES!
CO NOCI MI ENTO Y CUMPLI MI ENTO CON L AS SIG UI ENTES PRECAUCI ONES SO N L A RESPO NSABIL IDAD EXCL USIVA DEL USUARIO DE
ESTE EQ UIPO.
1. EL EQUI PO DEBE ESTAR CON ECTADO A TIE RRA EN FORMA
DEBI DA.
2 . EL AL AMBRADO PA RA EL SUMINISTRO DE L A FUERZA
EL ECTRI CA Y DISPOSI TIVOS CORRESPO NDIENTES DEBEN
TENER SUS FUS IBL ES Y SER DEL TAMANO O CAPACIDAD
Q UE COR RESPON DE A ESTE EQUIPO.
3 . DEBE DESCO NECTA RSE LA FUERZA ELEC TRI CA ANTES
DE ABRI R L AS CAJAS ELECTRICA S O HA CER CUAL QUIER
TRABAJO EN LO S CO MPO NENTES EL ECTRI COS.
4 . LOS DISPO SITIVOS DE MANDO D EBEN MANTENERSE EN PERFECTO ESTADO DE FUNCIONAMIEN TO PARA E VITAR EL
SOBREC ALENTAMIEN TO ACCI DENTAL O EL DANO AL
P ERSONAL QUE ATE INDE EL EQ UI PO.
6 . VENT AND DRA IN PRO VISIO NS MUST NOT BE RESTRICTED.
5 . ESTE EQ UIPO NO DEBE S ER USA DO C UANDO NO HAY QUIEN

L O ATI ENDA.
7 . AIR AN D FLUID SUPPLY SERVICE PROVISI ONS MUST ALWAYS

BE SH UT OFF BEFOR E DI SCONNECTI NG OR SERVICING THIS
EQUIPMENT.
6 . LAS DI SPOSIC IONES SOBRE EL SER VICIO DE DRENAJE

O PURG A NO ESTAN R ES TR INGI DAS UN ICAMENTE AL FL UJO
CO RRECTO D EL FL UIDO.
THIS SI GN MUS T NOT BE REMOVED OR CAMOUFLAGED

DURIN G USE OF THI S EQUIPMENT.
7 . LAS DISPO SICI ONES O C ONEXI ONES DE SUMINISTRO

DE FLUI DO Y AIRE D EBE N CERRARSE SIEMPRE ANTES
DE DESCO NECTAR O S ERVIR EL EQ UIPO.
ESTA AD VER TEN CIA O SENAL NO DEBE QUITARSE
O TAPARSE MIENTRAS SE USA EL EQUIPO.
PAR T NO. 52 2- 00 20 5-0 0
P ART NO. 52 2 -00 20 5-0 1
21 7/16"
15 1/8"
6 7/16"
3 3/4"
13"
28"
2 3/4"
2 3/4"
11 3/4"
Closed Circuit
3 9/16"
1 15/16"
COOLING WATER OUT
FROM PROCESS
COOLING WATER IN
TO PROCESS
PROCESS WATER VENT

THIS EQUIPM ENT CO NTAI NS FLUID, PIPING AND CONNECTIO NS
W HI CH M AY BE EXTREMEL Y HOT AND COULD CAUSE SERIOUS
B URNS AND PERSONAL INJURY.
R ECO GNITION OF AND COM PLIANCE W ITH TH E FOLL OWING
P RECAUTIONS ARE THE SOLE RESPONSIB ILITY OF THE USER
O F THIS EQ UIPMENT.
3 . ELECTRIC POWE R SOURCE M UST BE DISCONNECTED PRIO R

TO O PENING ANY ELECTRIC ENCL OSURE OR WORKING ON
ANY EL ECTR IC COM PONENTS.
28 3/4"
ESTE EQUIPO CO NTIENE FLUIDO , TUB ERI A Y CONEXIONES QUE

PUEDEN ESTAR PEL IGROSAM ENTE CALIENTES!
CONOC IMI ENTO Y CUMP LIM IENTO CON L AS SIG UIENTES PRECAUCIONES SO N LA RESPONSABIL IDA D EXCL USIVA DEL USUARIO DE
ESTE E QUIPO .
1 . EL EQUIPO DEBE ESTAR CONECTADO A TIERRA EN FORM A
DEBI DA.
1 . EQUIPM ENT MUST BE PROPERL Y G RO UNDED.

2 . EL ECTRIC POWER SUPPLY WIRIN G AND DEVICES MUST BE
PROPERLY FUSED AND SIZED TO MEET REQUIREM ENTS OF
THIS EQUIPM ENT, AND ALL APPL ICABLE CODES.
4 . AL L CO NTROL DEVICES MUST BE MA INTAINED IN PROPER

WO RKING CO ND ITION TO A VO ID ACCIDENTAL O VERHEATING
OR DANGER TO O PERA TI NG PERSONNEL.
5 . THIS EQ UI PMENT MUST NOT BE USED WHIL E UNATTENDED.
2. EL AL AMBRADO PARA EL SUM INISTRO DE L A FUERZA

EL EC TRICA Y D ISP OSITIVOS CORRESPONDIENTE S DEBEN
TENER SUS FUSIBLES Y SER DEL TAM ANO O CAPACIDAD
Q UE CORRESPONDE A ESTE EQUIPO.
3. DEBE DESCONECTARSE LA FUERZA ELECTRI CA ANTES
DE ABRI R LAS CAJAS EL ECTRICAS O HA CER CUAL QUIER
TRABAJO EN LOS COM PONENTES E LECTRI COS.
4. LOS DI SPOSITIVOS DE M AND O DEBEN MANTENE RSE EN PERFECTO E STADO DE FUNCIONAM IENTO PAR A EVI TAR EL
SOBRECAL EN TAM IENTO ACCIDENTAL O EL DANO AL
PERSONAL Q UE ATEINDE EL EQUIPO.
6 . VENT AND DRAIN PROVIS IONS M UST NOT BE RESTRICTED.
5. ESTE EQUIPO NO DEBE S ER USADO CUANDO NO HAY QUIEN

LO ATI ENDA.
7 . AI R AND FLUID SUPPLY SERVICE PROVI SI ONS MUST ALWAYS

BE SHUT OFF BEFO RE DISCONNECTING OR SERVICING THIS
EQUIPMENT.
6 . L AS DI SPOSICIONES SOB RE EL SERVICIO DE DRENAJE

O PURGA NO ESTAN RESTRI NGIDAS UNICAM ENTE AL FL UJO
CO RRECTO DEL FL UIDO.
THI S SIGN MUST NOT BE R EM OVED OR CAMO UFLAGED

DURING USE OF THI S EQUIPMENT.
27 1/8"
7 . L AS DISPO SI CIONES O CONEXIO NES DE SUMINISTRO

DE FLUIDO Y AIRE DEBEN CERRARS E SIEMPRE ANTES
DE DESCONECTAR O SERVIR EL EQUIPO.
ESTA ADVERTENCIA O SENAL NO DEBE QUITARSE
O TAPARSE MIENTRA S SE USA EL EQUIPO.
PART NO . 5 22- 00 205- 00
PART NO. 52 2-0 020 5-01
26 1/16"
21 7/16"
PROCESS WATER IN
15 1/8"
6 7/16"
3 3/4"
13"
28"
2 3/4"
2 3/4"
11 3/4"
Model
number
460 / 230
2010,
9 kW heater
Page 10
hp
1
2
3
5
7
kW
0.56
0.75
1.50
2.24
3.73
5.60
Pump
lpm
gpm
30
113.6
35
132.5
50
189.3
60
227.1
75
283.9
90
454.2
H
psig
25
30
30
35
54
63
kPa
172.4
206.9
206.9
241.3
372.3
434.4
in.
Dimensions
W
D
cm in. cm in. cm
28 73.0 13 33
Shipping
weight
lbs. Kg
210
96
240
109
28 71.1
Figure 2
Typical Royal Upright Series Water Temperature Control Unit and Specifications
7 /8
4948"
3 3/4"
28"
13"
Model
number
460
230
2012,
9 kW heater
letter
hp
C
D
1
F
2
G
3
H
5
J
7
K
10
kW
0.56
0.75
1.50
2.24
3.73
5.60
7.46
Pump
gpm
30
35
50
60
75
90
120
in.
Dimensions
W
D
cm in. cm in. cm
48
122
H
lpm psig kPa
113.6 25 172.4
132.5 30 206.9
189.3 30 206.9
227.1 35 241.3
283.9 54 372.3
340.7 63 434.4
454.2 55 379.2
13 33
Shipping
weight
lbs. Kg
210
96
240
109
270
123
28 71.1
Figure 3
Royal Series Unit Full-Load Amps
Model
hp
kW
0.75 hp 0.56 kW
1.00 hp 0.75 kW
2.00 hp 1.50 kW
3.00 hp 2.24 kW
5.00 hp 3.73 kW
7.50 hp 5.60 kW
10.00 hp 7.46 kW
9 kW heater
12.7 amps
13.1 amps
14.7 amps
16.1 amps
18.9 amps
22.3 amps
26.0 amps
Full-load amps at 460 volts

12 kW heater 18 kW heater 24 kW heater 36 kW heater 48 kW heater
16.5 amps
24.0 amps
31.6 amps
47.4 amps
62.4 amps
16.9 amps
24.4 amps
32.0 amps
47.8 amps
62.8 amps
18.5 amps
26.0 amps
33.6 amps
49.4 amps
64.4 amps
19.9 amps
27.4 amps
35.0 amps
50.8 amps
65.8 amps
22.7 amps
30.2 amps
37.8 amps
56.6 amps
71.6 amps
26.1 amps
33.6 amps
41.2 amps
57.0 amps
72.0 amps
30.0 amps
37.0 amps
45.0 amps
60.0 amps
75.0 amps
Page 11
Shipping Information
2-1
Unpacking and Inspection

You should inspect your Sterling/Sterlco Royal Series temperature
control unit for possible shipping damage. If the container and
packing materials are in re-usable condition, save them for
reshipment if necessary.
Thoroughly check the equipment for any damage that might have
occurred in transit, such as broken or loose wiring and
components, loose hardware and mounting screws, etc. In case of
breakage, damage, shortage, or incorrect shipment, refer to the
following sections.
2-2
In the Event of Shipping Damages

Important!
According to the contract terms and conditions of the Carrier,
the responsibility of the Shipper ends at the time and place of shipment.
Notify the transportation companys local agent if you discover
damage.
Hold the damaged goods and packing material for the
examining agents inspection. Do not return any goods to
Sterling before the transportation company inspection and
authorization.
File a claim against the transportation company. Substantiate
the claim by referring to the agents report. A certified copy of
our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was
prepaid, contact Sterling at (262) 641-8610 for a receipted
transportation bill.
Advise Sterling regarding your request for assistance and
to obtain an RGA (return goods authorization) number.
Page 12
2-3
If the Shipment is Not Complete

Check the packing list. The apparent shortage may be intentional.
Back-ordered items are noted on the packing list. You should have:
Sterling/Sterlco Royal Series water temperature control unit
Bill of lading
Packing list
Operating and Installation packet
Electrical schematic and panel layout drawings
Component instruction manuals
Re-inspect the container and packing material to see if you missed
any smaller items during unpacking. Determine that the item was
not inadvertently taken from the area before you checked in the
shipment. Notify Sterling immediately of the shortage.
2-4
If the Shipment is Not Correct

If the shipment is not what you ordered, contact the Sterling
parts and serive departments immediately at (262) 641-8610.
Include the order number and item. Hold the items until you
receive shipping instructions.
2-5
Returns
Important!
Do not return any damaged or incorrect items
until you receive shipping instructions from Sterling.
Page 13
2-6
Uncrating Your New Royal Series System

Royal Series water temperature control units are shipped
fastened to a skid and covered with a cardboard box.
Carefully remove the staples on the bottom of the box, lift off
the box, and remove the bolts holding the unit to the skid.
Caution!
Be careful when cutting straps.
Straps may spring back and cause injury!
From the side, slip two lifting straps between the skid and
temperature control unit. Spread the straps from the center line
so it is balanced.
Loop the straps over a fork truck fork. Lift slowly and only
high enough to clear the skid. Use a pry bar if necessary to
remove the skid from the unit.
Carefully slide the skid from beneath the unit and lower the
unit. Lower slowly. The unit should land on its casters and can
be rolled into position.
Retain the crating in case reshipment is necessary due to
hidden shipping damage.
Page 14
- Notes -
Page 15
3
3-1
Installation
Installation Location Considerations
Royal Series systems are portable and can be installed almost
anywhere. As with all equipment installations, follow all
applicable codes and regulations.
The recommended ambient temperature range for Royal Series
installations is from +14F (-10C) to a maximum operating
ambient temperature of 131F (55C). Recommended ambient
storage temperature range is from -13F to 149F (-25C to
65C). If storing the unit below freezing temperatures, make
sure the unit has an antifreeze mixture circulated inside.
Provide a minimum of twelve inches (12 or about 30 cm)
clearance on all sides of the cabinet to allow circulation of
cooling air.
Locate the unit as close to the process as is practical.
3-2
Process Approach Temperature Considerations

If the differential (U) between COOLING WATER IN and TO
PROCESS temperatures is less than 10F (7C), consult our Sales
Department for advice on how to control low approach
applications.
3-3
External Piping Sizing Considerations

All external hose and piping should be adequately sized to
assure minimum external pressure drop.
Low external piping pressure drop is needed for best operation.
Page 16
Note: Use a backup wrench to support Royal Series system

piping when making process piping connections.
CAUTION
All external valves, fittings, and hoses must be rated at a minimum of

150 psig and 250F (1,034.25 kPa/10.34 bars and 121C).
The exception is when the temperature control unit
is optionally rated for 300F (149C) operation;
external valves fittings and hoses must then be rated at a minimum of
3-4
Piping Considerations for Permanent

Installations
Sterling recommends an optional (or customer-installed) strainer
on the COOLING WATER IN inlet.
The unit must have at least 16 psig (110.32 kPa/1.1 bars) water
supply pressure to prevent pump cavitation that can be caused by
the water flashing to steam. To avoid damage to the pump or
other components, make sure that maximum supply pressure does
not exceed 55 psig (379.2 kPa/3.79 bars).
Keep restrictions to a minimum by using proper inlet pipe sizing. If
the water supply piping is larger than , reduce the size at the
unit. The table below contains the pipe sizes that are used in the
unit.
Pipe sizes for hp to 10 hp (0.56 kW to 7.46 kW) units
Location
Size in inches NPT
To Process
1
From Process
1
Cooling Water In
Cooling Water Out

- depends on solenoid used -
Common black pipe is recommended for permanent installations.

Royal Series water circuit piping is primarily ferrous (iron) and
reacts electro-chemically with non-ferrous metallic materials such
as copper. Some water contains dissolved minerals that greatly
accelerates the reaction between dissimilar metals.
Page 17
Ferrous piping is recommended to minimize galvanic action. If

piping must be copper, use dielectric unions at the unit.
3-5
Piping Considerations for High Mobility

Installations
Mobile Royal Series systems must use high quality hose rated for
at least 150 psig and 250F (1,034.25 kPa/10.34 bars and 121C).
Special 300F (149C) high temperature Royal Series systems
must use hosing rated at 150 psig and 300F (1,034.25 kPa/10.34
bars and 149C) or greater.
Quick disconnects may be used for mobility, although they cause
a drop in pressure. If used, they must be sized carefully to
minimize pressure drop. Dont use quick disconnects with check
valves unless absolutely necessary.
CAUTION
Non-relieving quick connect fittings or check valves on the water supply

must have a pressure relief piped to the drain.
Failure to do so could result in a dangerous over-pressure condition!
3-6
Process Water Considerations
Raw Water
Water treatment is vital in any piping system. In some cases, raw
water may be used in the system without problems; in other cases,
it can result in large deposits of scale and corrosion.
Sterling offers a complete line of water treatment equipment.
Contact your Sterling sales representative for water testing and
treatment options.
Distilled Water
Non-ferrous (brass, copper, or high-temperature plastic) piping is
recommended for distilled water processes.
Page 18
Deionized Water
Stainless steel (316 SS minimum) or PVC plastic components must
be used with deionized water. Sterling recommends stainless steel
because of the temperature constraints with plastic.
3-7
Making Process Water Connections
Closed Circuit/Direct Injection

On the back of each unit, the connections are labeled appropriately.
For Direct Injection units connect the TO PROCESS hookup to the
entrance of the process and the FROM PROCESS hookup to
the exit of the process. Connect the COOLING WATER
IN to your plant water supply. Connect the COOLING WATER
OUT line to an open drain, or to the return line of
your central water system.
For Closed Circuit units make the connections as stated above, and
if there is a separate supply for the process and cooling make the
following connections. Connect the PROCESS WATER
SUPPLY hookup to the water source for the process. Connect the
PROCESS WATER VENT hookup to return the water back to
the process source.
Make sure you carefully select the connecting lines and
connectors between the temperature control unit and the
process to suit the needs and requirements of your application.
If your unit has a maximum operating temperature of 250F
(121C), the connecting lines and connectors should have a
service rating of at least 250F (121C) and 150 psig (1,034.25
kPa/10.34 bars). If it has a maximum temperature of 300F
(149C), the lines and connectors should have a service rating
of at least 300F (149C) and 150 psig (1,034.25 kPa/10.34
bars).
TO PROCESS 1 NPT
This is the outlet for the tempered water leading to the process
being controlled.
Page 19
FROM PROCESS 1 NPT

Water from the process re-enters the Royal Series system to be
tempered and re-circulated back into the process.
3-8
Making Cooling Water Connections
WATER IN
The cooling water supply inlet from a cooling tower, a chiller, or a
city water supply.
CAUTION
If a non-relieving device such as a regulator, ball valve,

or check valve is installed on the WATER IN line,
you MUST install an expansion tank
of at least gallon (about 2 liters) capacity.
Failure to do so can result in system overpressure from thermal expansion.
Install the tank configured as shown below:
Expansion
tank
Royal Series
unit
Non-relieving
device
Check the expansion tank frequently to make sure it is not flooded.
Page 20
Water Out
Size Depends on Solenoid Used
The cooling water outlet leading back to the cooling tower, chiller,
or drain.
Net supply pressure must be between 25 psig and 55 psig (172.38
kPa/1.72 bars and 379.2 kPa/3.79 bars). Net supply below 15 psig
(103.43 kPa/1.03 bars) may allow water to flash to steam, cavitate
the impeller, and damage the pump, which prevents the unit from
cooling properly. Operation above 55 psig (379.2 kPa/3.79 bars)
may cause premature opening of the relief valve from pump
pressure and pressure surges.
PRESSURE RELIEF
The pressure relief valve, located at the back of the unit, is prepiped to approximately four inches (4 or 10 cm) above the floor.
This piping reduces the chance of scalding nearby personnel if the
relief valve should trip.
3-9
Making System Purge Connections

Royal Series systems equipped with the System Purge option have
a compressed air inlet marked MOLD PURGE. Connect to a clean,
dry 100 psig (689.50 kPa/6.90 bars) air line. Install your own
shutoff valve to prevent process liquid from backing up into the
plant air piping if the compressed air is turned off and the check
valve fails. Dont depend on the solenoid valve to hold water
pressure in the temperature control unit.
Page 21
Figure 4
Typical Piping Schematic
Page 22
Figure 5
Pump Curves; 60 Hz
Pump Curves; 50 Hz Consult Factory for 10 hp Curves
Figure 6
Pressure Drops
Model
hp
kW
0.75 hp 0.56 kW
1.00 hp 0.75 kW
2.00 hp 1.50 kW
3.00 hp 2.24 kW
5.00 hp 3.73 kW
7.50 hp 5.60 kW
10.00 hp 7.46 kW
9 kW htr
12.7 amps
13.1 amps
14.7 amps
16.1 amps
18.9 amps
22.3 amps
26.0 amps
Pressure drop flow and loss

flow lpm
flow gpm
loss psi
30.0 gpm
0.0 psi
113.6 lpm
35.0 gpm
1.0 psi
132.5 lpm
50.0 gpm
1.5 psi
189.3 lpm
60.0 gpm
2.0 psi
227.1 lpm
75.0 gpm
2.5 psi
283.9 lpm
90.0 gpm
5.0 psi
340.7 lpm
120.0 gpm
5.0 psi
454.2 lpm
loss kPa
0.0 kPa
6.9 kPa
10.3 kPa
13.8 kPa
17.2 kPa
34.4 kPa
34.4 kPa
Page 23
3-10 Making Electrical Connections

Royal Series systems are designed for three-phase voltage
operation. Refer to the unit nameplate for proper voltage and
amperage requirements.
Make sure you provide a correctly sized and protected supply of
electrical power to the unit.
Important!
Refer to National Electric Code (NEC) Article 430-24 through 430-26
for proper feeder conductor and supply disconnect sizing.
Maintain a safe ground and disconnect the power supply before
servicing the unit. A qualified electrician should make electrical
connections, and disconnect and lock out electricity using OSHA
29CFR 1910.147 standards when you need a service call.
Check serial tag voltage and amperage requirements and make sure
your electrical service conforms before making any electrical
connections. Total running amps for Royal Series systems are
listed on the nameplate. Customer connections can be run to the
supply terminals from either side of the unit. Make sure that all
three phases are wired correctly. If not wired properly, the unit will
run backwards. Again, check the unit nameplate for correct
voltage and amperage.
DANGER
Improper electrical connections

can damage the unit and cause
serious operator injury or death!
Page 24
Bring properly sized power leads and ground from a fused

disconnect (installed by your electrician) to the unit. Provide
external overcurrent protection to the unit, using circuit breakers or
fuses. If you use fuses, make sure that they are dual-element timedelay fuses, sized according to your electrical code. Make sure that
all electrical connections are tight.
Important!
1. Electrical connections must comply with all applicable electrical codes.
2. The temperature control unit must be grounded in accordance with NEC
Article 250.
3. Voltage must be within plus or minus ten percent (10%) of the nameplate
rating.
4. Make sure your installer provides external protection.
Page 25
Figure 7
Typical Electrical Wiring Schematic
Please refer to the electrical wiring diagrams supplied

with your units Customer Information Packet.
Page 26
4
4-1
Identifying Controls and Features

Identifying Mechanical Controls and Features
To and From Process Probes

Two (2) 1,000-ohm (1 K) platinum RTD probes are included
with your Royal temperature control unit. One is located
downstream from the heater to sense To Process temperature; the
other probe is located upstream from the pump to sense From
Process temperature.
Safety Thermostat
The safety thermostat mounted on the side of the heater tank
protects against thermal runaway. The thermostat guards against
the unlikely event of runaway heating. If overheating occurs, the
safety thermostat shuts down heater outputs. The unit continues to
pump water through the system to prevent heater damage. Sterling
recommends that you install an audible or visual alarm to the
terminals provided. Factory installed alarms are available; see the
electrical schematics in your Installation Packet for more
information.
Pressure Relief Valve

If the combined pressure of the cooling supply water and pump
discharge exceeds 150 psig (1,034.25 kPa/10.34 bars), the pressure
relief valve opens and relieves the pressure. This is a nonadjustable ASME construction valve with a stainless steel spring.
Important!
Route a pipe from the pressure relief valve
to a suitable drain to reduce potential scalding hazard.
The drain line must not have any restrictions or back pressure.
Page 27
Low Pressure Cutout Switch

This switch, set at 16 psig with a 2 psig differential (110.3 kPa/
1.10 bars with a 13.79 kPa/0.14 bars differential) shuts down the
unit if the COOLING WATER IN or MAKEUP water pressure
drops below 16 psig (110.3 kPa/1.10 bars).
Pumps
Pumps range in power from hp to 10 hp (0.56 kW to 7.46 kW)
and are equipped with 3-phase ODP motors and seal flush lines as
standard.
The pump is a bronze-fitted close-coupled centrifugal type. It
features a split case design to facilitate replacement of the seal. It
has a high output capacity with excellent discharge pressure
helping it facilitate turbulence to maximize heat transfer, and is
well suited for the conditions under which it was designed to
operate.
Heaters
The specially designed 9 kW three-phase low watt density
electrical immersion heater heats the water, and the controller
regulates the temperature. The standard heater has an incolloy
sheath for best heat transfer and low fouling properties.
Low watt density immersion heaters at 12 kW, 18, 24 kW, 36 kW,
and 48 kW are available options for these models, depending upon
the heating needs of the process. All models are built to provide
full or partial heat as required by the process and determined by the
controller, providing more precise temperature control.
Solenoid Valves
Royal Series systems use rugged, industrial design solenoids with
replaceable coils and/or internal components. Depending on
required cooling capacity, solenoid valves are available in sizes
ranging from 1/4 to 3/4; 1/2 x 9/16 and 3/4 x 3/4 solenoid valves are
slow-closing.
Page 28
Comment [JSB1]: Page: 6
Motorized Modulating Valves

Optional
Optional motorized modulating valves are recommended for large
cooling applications where the process temperature is very near the
cooling water supply temperature and the temperature controller
unit pump is used as a booster. The gradual shutoff they provide
also eliminates water hammer. The option includes a complete
valve and motor package in place of a long-life solenoid valve.
The motorized modulating valve has infinite positioning. It fully
opens in one (1) minute and fully closes in 15 seconds.
Water Hammer Arrestor (Shock Stop)

Optional
Shock waves from fast-operating solenoid valves may damage
some process systems. For these applications, a welded metal
bellows-type shock stop with a pre-charged and sealed nitrogen
blanket can be installed in the cooling piping.
Pump Starter
Royal Series high quality IEC-rated pump motor starters are
industrial grade motor controls with overload protection and
manual reset.
Transformer
High quality industrial design transformers are specified to suit
incoming voltage on the application and provide 115 VAC control
voltage. The 115 VAC circuit is protected by primary fusing and
secondary grounding.
Heater Contactor
Your Royal Series unit uses high-quality IEC-rated industrialgrade electromechanical contactors for heater controls.
Page 29
Cooling
The controller automatically regulates cooling by opening and
closing the solenoid valve or modulating valve. For direct
injection, the unit cools by removing the required amount of warm
water from the system. This process permits an equal amount of
cool plant water to enter the system well ahead of the pump,
allowing it to blend with the system water. The water supply
temperature governs the minimum operating temperature of the
unit.
For closed circuit operation, the unit cools by automatically
releasing cooling water through the tubes of the specially designed
tube bundle heat exchanger in each zone. The process fluid, such
as water, glycol, or other similar fluid, is circulated through the
shell of the heat exchanger.
Note: The plant water supply temperature governs the minimum
operating temperature of the unit.
Electricals
The pump motor and the immersion heater operate on three-phase
50/60 cycle nominal voltages with the control circuit operating at
115V single phase. The control circuit voltage is provided by a
single phase machine tool transformer with a grounded secondary.
The 115V control circuit and controller outputs are fuse protected.
The pump motor is controlled by a full voltage magnetic nonreversing motor starter, with fused branch circuit overcurrent and
thermal overload protection.
Automatic Vent
This feature automatically triggers the purging of air from the
system before you start the unit. The vent actuates the solenoid
valve, and forces trapped air and water out through the drain,
properly filling and priming the unit prior to startup. Complete
venting is necessary to prevent damage to the pump and heater.
The vent process is controlled through a timer. If you have a large
process, you may need to complete the venting process by pressing
the VENT button on the front-mounted switch panel.
Page 30
Pressure Switch
A pressure switch built into each unit keeps the system from
starting until the water supply is turned On and subjected to the
minimum water supply pressure. This feature protects the pump
seal and the heater from damage through attempted operation
without water. The pressure switch is set at approximately 16 psig
(110.32 kPa/1.10 bars) for 250F (121C) units or 55 psig (379.23
kPa/3.79 bars) for 300F (149C) units prior to leaving the factory.
4-2
The Microprocessor Controller

These temperature control units can be manufactured with different
controllers (M2B, M2B+, or any off-the-shelf PID controller).
Please refer to your enclosed controller manual for a detailed
description of the operation of the controller.
4-3
Operating the Unit with the Controller

M2B
Start Up
Disconnect Switch
1. Turn disconnect switch to ON position.

2. Press START. The unit will automatically vent for approximately one
minute.
3.
4. If needed, press and hold the vent button to purge any additional air
from the process loop.
5. Set process temperature (SETPOINT) by pressing the
Up
Arrow or
Down Arrow keys.
6. If the unit does not maintain its process value, allow your process to
reach the set point temperature. Refer to the controller manual
should the controller need to be tuned.
Shut Down
1.
2.
Push STOP button.

Turn disconnect switch to OFF position.
Page 31
M2B+
Start Up
Disconnect Switch
1. Turn disconnect switch to ON position.

2. Press START. The unit will automatically vent for approximately one
minute.
3. If needed, press and hold the vent button to purge any additional air
from the process loop.
4. Set process temperature (SETPOINT) by pressing the
Up
Down Arrow keys.

Arrow or
5. If the unit does not maintain its process value, allow your process to
reach the set point temperature. Then Autotune the control by
pressing
key.
Shut Down
1.
2.
4-4
Push STOP button.

Turn disconnect switch to OFF position.
Communications
A connection port on the electrical cabinet permits easy hook-up to
the host computer for RS-232C and RS-485 communications. The
connection port is a direct pin-to-pin extension from the back of
the controller. For pin outs, consult the enclosed controller owners
manual.
Page 32
5
5-1
Startup and Operation

Introduction
The checklist below outlines start-up procedures for Royal Series
water temperature control units. This list assumes that installation
information located in this manual has been read and followed.
5-2
Startup Checklist
Check the shipping papers against the serial tag to make sure
that system size, type, and voltage is correct for the process
under control.
Check the transformer primary voltage connections to be sure
they are configured for the electrical power you are using. The
voltage at the main power connection must be within plus or
minus ten percent (10%) of the voltage listed on the serial tag.
Electrical connections must conform to all applicable codes.
Make sure that a qualified electrician checks all electrical
connections.
The safety thermostat is preset at the factory to 250F or 300F
(121C or 149C), depending on configuration. It trips at 265F
or 315F (129C or 157C), depending on configuration.
The relief valve should be piped to an open, unrestricted drain.
TO PROCESS, FROM PROCESS, WATER IN, WATER OUT,
and MOLD PURGE connections should be complete.
CAUTION
Only use components rated at a minimum of

All outer panels must be in place.
All external process valving should be set for proper operation
of the unit.
Cooling and/or makeup water between 16 psig and 55 psig
(110.32 kPa/1.1 bars and 379.2 kPa/3.79 bars) must be
available for the unit to operate properly.
Page 33
Connect the main power to the unit disconnect switch, and

press the START switch to check for proper pump rotation
direction as described in Section 5-6. Pump rotation should be
clockwise, viewed from the motor end.
Check your work and proceed to the Startup Procedure
section on the following page.
5-3
Starting the Temperature Control Unit

Turn ON the water supply, turn the rotary disconnect to the ON
position, and push the START button.
The unit automatically executes a one-minute venting sequence
to expel air trapped in the process piping. Sterling recommends
a longer venting sequence on larger process systems. Press and
hold the VENT button to force the cooling/vent valve open and
eliminate air trapped in the process piping in larger process
systems.
The controller is OFF and the Vent Cycle indicator is lighted
during the vent sequence.
Set the controller to the process temperature.
Refer to the enclosed controller manual for details regarding
the auto-tuning process.
Watch the drain for any bubbles or erratic flow, which
indicates if the system has been properly vented. If the stream
is steady, the unit was properly vented and all air is out of the
system.
Operate the unit, checking for anything unusual that could
indicate improper operation.
Note: You can stop the Royal Series temperature control unit at
any time by pressing the STOP button.
Page 34
CAUTION
1) Your Royal Series system operates with hot water under pressure. To reduce
the risk of scalding:
Always wear work gloves and safety glasses when operating the unit.
Never operate the unit with panels or shields removed.
Pipe the relief valve to an open drain.
Never install a fitting or hose that is rated less than 150 psig and 250F
(1,034.25 kPa/10.34 bars and 121C).
2) To reduce the risk of electrical shock:
5-4
All electrical installation and repairs should be done by a qualified

electrician.
Ground the unit in accordance with electrical codes.
Never attempt any repairs without first opening and locking out the main
disconnect.
Never deactivate or neutralize any safety device.
Sequence of Operation
The simplicity of design and the highly engineered controller make
this unit almost self-operating. The START, STOP, and VENT
buttons and the temperature controller buttons are all that is
required to operate this unit.
After you complete all connections, turn the water supply ON, then
turn control power ON. The unit automatically vents for a preset
time of one (1) minute. If you need additional vent time, press the
VENT button on the control panel.
As the water comes in the water supply line, the water must enter
the pump, up through the tank and out through the TO PROCESS
line, through the process, back through the FROM PROCESS line,
and through the solenoid line and out the drain line.
At this time, watching the drain for bubbles or erratic flow will
indicate whether or not the system has been properly vented. If a
steady stream flows from the drain line, it is certain that all the air
is out of the system. If you have the unit connected to a central
system, watch the pressure gauges for erratic pressure changes. If
the gauge is steady, all the air is out of the system.
Page 35
TCU systems provide temperature control on processes by

directly heating the process water and injecting cooling water
into the process water.
When the unit is energized, the pump starts and a one minute
vent sequence opens the cooling/vent valve to remove any air
trapped in the process piping.
If the cooling water supply pressure is insufficient, the low
cooling water pressure cutout switch (set at 16 psig, 10 psig
differential [110.32 kPa/1.10 bars, 68.95 kPa/0.69 bars
differential]) opens, the LOW WATER PRESSURE indicator
lights, and the unit does not operate until the pressure is 16 psig
(110.32 kPa/1.10 bars) or more. You need at least 16 psig
(110.32 kPa/1.10 bars) for the best cooling capacity and to
prevent water boiling in the process circuit at high
temperatures, particularly at the pump suction.
After venting, the microprocessor controller monitors the TO
PROCESS RTD probe, cycling open the cooling/vent valve to
discharge warm water or energizing the immersion heater to
maintain the process set temperature.
5-5
Checking Motor Rotation Direction

Check for correct pump rotation direction by looking at the top of
the motor. Press the START button and the STOP button, and note
the direction that the motor turns. Rotation should be clockwise
when viewed from the motor end.
Note: Make sure that a qualified electrician performs the
following steps.
To change rotation direction:
5-6
1.
Disconnect and lock out power at the fused disconnect.
2.
Reverse any two incoming leads at the power terminal

blocks.
3.
Do not switch leads at the motor or motor starters.
Shutting Down the Temperature Control Unit

Cool the unit down by selecting a set point of zero (0 ). Let the
unit stabilize at one temperature close to the incoming water
temperature, then press the STOP button. Now press the VENT
button to relieve any remaining pressure in the system.
Page 36
- Notes -
Page 37
Unit Maintenance
!
CAUTION
Never attempt to service a unit until a qualified

electrician has opened and locked out the main
disconnect using OSHA 1910.147 standards.
The water supply should be turned off and internal
pressure should be relieved before you remove panels.
All electrical connections must be done by a qualified
electrician.
WARNING
Disconnect all power to the unit, let the unit

cool down, and turn off the water prior to any
servicing.
Failure to do so can result in SERIOUS INJURY
OR DEATH!
6-1
Preventive Maintenance
Draining
Drain the unit thoroughly if you are taking it out of service for a
long period of time, or you expose it to freezing. Drain plugs are
provided at the base of the heater tank and at the base of the pump.
Page 38
Periodic Checks
Every Six Months
Inspect all electrical connections for secure attachment and for safe
and secure ground connections. Inspect the power cable, especially
at the entrance point to the unit. This inspection should be made by
a qualified electrician. Check for leaks, especially under the pump,
as it may indicate a worn pump seal.
6-2
Corrective Maintenance
Pumps and Seals

Before leaving our factory, we test each unit extensively, then we
calibrate each unit. Afterwards, the unit is drained and blown out
with air to remove water from piping systems. If the unit is
allowed to stand idle for a long time before being installed in your
factory, the housing gasket at the pump can dry out and can
possibly leak when the unit is started. In most cases these gaskets
will soon swell and form a tight seal. In other cases, it may be
necessary for you to tighten the pump bolts to stop a leaking
condition.
Pump seal surfaces can separate slightly because of rough handling
or from vibration during transit. This could cause a leak at the
pump seal when the pump is started, but in most cases the surfaces
will mate again after the pump is allowed to run for a short period
of time. If they do not reseal, you may need to open the pump and
free the seal by hand. It is seldom necessary to install a
replacement seal in a new unit unless the seal has been damaged
because the unit was started without water.
Our pump seals have a long period of service life. Some
conditions, of course, can shorten seal life, including the presence
of grit, operation of the unit without water, sustained high water
temperature, or presence of certain chemicals in the water. Our
pump seal assembly has been developed to resist abrasive particles
that are present in many water systems. This is done by a special
flushing system that uses water exiting the pump to constantly
wash the seal area.
Page 39
It is also fitted with high temperature flexible components for

maximum heat resistance. These same components remain flexible
even at low temperatures. Thus, the standard seal is a fine
combination of heat resistant and wear resistant components.
Unfortunately, even under normal use, the seal will eventually
wear and require replacement.
A small puddle underneath the unit is a sign of rotary seal wear,
and if investigation confirms the pump as the source, the seal
should be replaced as soon as practical. The water slinger is
intended to provide temporary protection against this, but a
continued and substantial leak will ruin the motor bearing and
cause further damage.
After the unit has been in service for a period of years where
abrasive conditions are present, you may find that the pump
bracket (the top half of the pump casting), can be eroded away in
the area around the seat of the rotary seal. This area should provide
a straight, smooth bearing surface for the cup seal. Should your
casting show signs of erosion in this area, the casting needs to be
replaced. The replacement cost of the casting is very modest
compared to the down time and maintenance cost for frequently
replacing the seal.
Under some conditions, the pump may not start. After turning off
the power supply, check the motor shaft to be certain it is free to
turn. By removing the drip cover on top of the motor, youll have
access to the end of the shaft. It has been slotted to make it easy to
turn with a screwdriver. If the shaft is free to turn, next check that
the motor overloads are set, check for blown fuses, and finally
check the power supply on each leg to the motor. A qualified
electrician should check the motor and its circuit.
Important!
If the pump motor wiring is disconnected for removal from the unit,
make sure that you check the actual rotation direction
when the motor is rewired to the unit.
A phase sensor does not always indicate proper rotation
if motor wire leads are reversed at installation.
Consult the elementary wiring diagram for more information.
Page 40
Heaters
Heaters may need to be cleaned chemically or mechanically to
remove deposits and dirt that reduce heat transfer and cause hot
spots. Hot spots cause premature heater failure. Install a new
gasket when reassembling. Make sure a qualified electrician
disconnects and reconnects heater wires.
Solenoid Valves
Clean annually, more often if using high mineral content water
or on high service level units.
Sluggish operation, excessive leakage, and/or noise indicate
cleaning is necessary. Inspect the components for excessive
wear while the valve is disassembled.
Rebuild kits are available from the Sterling Parts Department.
6-3
Restoring the Controller to Factory Setup

If the preset parameters on the controller have been tampered with
and it no longer properly controls temperature, you can restore the
controller to factory setup parameters. For more information on
controller restoration, consult the enclosed controller owners
manual.
6-4
Electrical Connections
Make sure that a qualified electrician inspects all electrical
components and connections every six (6) months for secure
attachment and ground connections. Inspect all wiring for fraying
or damage, especially power lines where they enter the unit. All
wiring connections must be tight.
Page 41
6-5
Safety Devices
Caution!
Make sure that only qualified electricians test safety devices!
Safety devices should be tested for function every six (6) months.
Perform the following procedures for testing:
Motor Overload
Disconnect main power. Open the electrical enclosure and rotate
the manual TEST button on the motor overload to the tripped
position. Close the enclosure and reconnect main power. Push the
START button. The unit should not start and the Pump Overload
indicator should illuminate.
Press the RESET button. The unit is now ready for operation.
Pressure Switch
With the unit running, program a set point of 30F (-1C). Allow
the process temperature to drop under 100F (38C). When the
process temperature reaches that point, turn off the water supply.
The pump should stop and the Low Water Pressure indicator
should illuminate. Turn the water supply on to reset the pressure
switch.
Adjusting the Pressure Switch
The pressure switch used in your Royal Series water temperature
control unit is factory set at 16 psig (110.3 kPa/1.1 bars). However,
if the process does not require the unit to operate at 250F (121C),
you can adjust the switch to meet your process needs.
Tools Required
Page 42
Small flat blade screwdriver
#2 Phillips head screwdriver
CAUTION
HAZARDOUS ELECTRICAL CURRENT PRESENT.

Maintain a safe ground and disconnect the power
supply before servicing the unit.
Make sure a qualified electrician makes electrical
connections; disconnect/lock out electricity using
OSHA 20CFR 1910.147 standards when servicing the
unit.
To adjust the pressure switch:
Using a small, flat-blade screwdriver, carefully remove the
plug at the top of the switch.
Figure 9
Pressure Switch
Side View and Top View
Phillips head screw
Under the plug is a Phillips-head adjusting screw:

Turn the screw counterclockwise to reduce the pressure.
- or Turn the screw clockwise to increase the pressure.
A quarter turn (90 rotation) approximates 15 psi (103.4 kPa/
1.0 bars).
Replace the plug on the top of the switch.
If the plug gets damaged, the switch is still sealed internally.
Page 43
Make sure that the high limit on the controller is set to the values
listed in the following table, based on the switch adjustment. This
prevents the pump from cavitating and damaging the seal, the
switch, and heater element(s).
psig
5 psig
10 psig
15 psig
kPa
34.4 kPa
68.9 kPa
103.4 kPa
Max. temp. F
227F
240F
250F
Max. temp. C
108C
116C
121C
Safety Thermostat
Disconnect main power. Open the electrical enclosure and
disconnect the neutral lead on the safety thermostat from the
terminal strip. Protect the stripped lead to prevent short circuits.
Close the enclosure, reconnect main power, and push the START
button. The heater should not turn on and the Over Temperature
indicator should illuminate. Disconnect main power before
reconnecting the thermostat lead.
6-6
Page 44
Cleaning and Storage
Inspect the unit daily for leaks. Wipe down the unit
periodically to remove dirt and dust buildup, especially the
motor casing.
Drain and flush the unit every six (6) months to remove
sediment buildup.
Completely drain the unit and carefully blow out the piping
with pressurized air before placing the unit in storage.
Troubleshooting
Condition
Possible cause
No power.
Unit does not turn on.
Wrong voltage supplied to unit.

Defective on/off switch.
Control circuit fuse blown.
Defective control transformer.
Broken or loose wire in pump
motor control circuit.
Pump motor contactor holding
coil is open.
Unit does not run.
Low water pressure light on.

Water supply to unit is turned
off.
Pump overload light on.
Pump running in reverse.
Low pump pressure.
High pump pressure.
Foreign matter in the system.

System has minimal back
pressure, and is operating at the
far end of the pump curve.
Foreign matter obstructing
system.
Solution
Check main disconnect, fuses,
wiring, and power lead to unit.
Voltage must be within plus or
minus 10% of nameplate rating.
Replace.
Replace.
Check transformer.
Locate and repair.
Repair or replace.
Check for at least 16 psig
(110.32 kPa/1.1 bars) water
pressure on WATER IN or CITY
WATER MAKEUP.
Open water supply.
Reset and test each leg for
balanced amp draws.
Verify proper rotation. If not
clockwise, reverse any two
incoming power leads.
Clean the system.
As long as there is satisfactory
process temperature control
there is no problem.
Clean the system.
Restricted water flow.
Check for closed valves etc. Be

sure all lines are properly sized.
System has high back pressure,

and is operating at the near end
of the pump curve; a low flow
condition.
As long as there is satisfactory

process temperature control
there is no problem.
Insufficient cooling or makeup

water pressure.
Pressure switch circuit is open.
Switch is broken.
Check for 25 psig (172.38

kPa/1.72 bars) water pressure
on WATER IN or CITY WATER
MAKEUP.
Jump power across switch and
see if unit starts. Replace switch
if needed.
Page 45
Condition
Possible cause
Undersized connectors/ water
lines.
Long connecting lines between
unit and mold.
Serpentine flow through mold.
Blocked water line in mold.
Temperature fluctuations/ rapid

cycling from hot to cold.
Quick disconnect fitting with

check valve.
Lime buildup in unit piping.
Faulty TCU.
Reversed probes.
Drain is plugged or excessive
back pressure is in drain line.
Faulty solenoid valve.
Controller Cool output relay
open.
Solenoid valve is not operating,
but COOL LED is on.
Unit overheats or does not cool.
Solenoid coil circuit is open.
Modulating valve is not
operating, but OUT2 LED is on.
Insufficient pressure differential
between cooling WATER IN and
OUT lines.
Cooling valve is undersize.
Relief valve leaks.
Foreign material under valve

seat.
High system pressure.
Unit runs continuously cooling or

heating, and cannot attain set
point.
Page 46
Unit under-sized for application.
Solution
Increase size of connectors/
water lines.
Move the unit closer to the mold
and shorten connecting lines.
Connect lines for parallel flow
instead of series flow.
Check mold for metal chips or
lime buildup. Clean mold.
Remove and replace fitting or
valve.
Clean or replace.
Check unit by connecting line
directly from To Process to From
Process line. Run unit to
determine if TCU controls set
point temperature.
Switch To and From Process
probes.
Clear drain line or eliminate
back pressure condition.
Test solenoid valve by pressing
VENT button and listen for valve
operation. Replace if faulty.
Replace output relay.
Set process temperature to
minimum and check for
magnetism on solenoid coil top.
Check coil resistance. If M
range, replace solenoid coil.
complete travel of valve; .
Find a means to get less back
pressure in the WATER OUT line.
Replace cooling valve with a
larger valve.
Manually open valve to clear
seat of material.
Reduce WATER IN or MAKEUP
water pressure.
Call sales representative.
Condition
Possible cause
Defective heater contactor.
Defective immersion heater.
Controller heat output open.
Heater contactor is not

energizing, but HEAT LED is on.
Immersion heater elements
dirty.
Unit does not heat/cannot
achieve set point.
Immersion heater element is
burned out.
OUT1 indicator is on, but no

voltage on heater contact.
Cooling valve is leaking.
Solenoid valve is not operating,

but COOL LED is on.
Magnetism on coil.
Faulty/dirty solenoid valve.
Solution
Visually inspect coil and
contacts; repair/replace
defective contactors.
Check resistance on all three (3)
legs of the heater with an ohm
meter. If not all equal, contact
factory for replacement heater.
Check the heater output with an
ohm meter to ground. It should
read in the mega-ohm range.
Infinite or zero readings indicate
a defective output.
maximum and check for control
voltage at heater contactor.
Remove heater and clean
elements.
Check heater tank for
scorched/discolored paint.
Check resistance on all three (3)
legs of the heater with an ohm
meter. Replace heater as
required.
Check for balanced amp draws,
and supply voltage. If not
present replace immersion
heater.
Replace relay board on
controller.
Dismantle valve and clean out.
magnetism on top of solenoid
coil.
Clean coil.
Press VENT button several times
to flush the valve.
Page 47
I
Automatic vent, 30
Available options, 89
Checking motor rotation
direction, 35
Cleaning and storage, 43
Closed circuit/direct injection
connections, 19
Communications, 31
Controller operation, 31
Cooling regulation, 30
Cooling water connections, 20
Copyright information, 2
Corrective maintenance, 3840
Cutout switch, low pressure,
28
Deionized water applications,
19
Disclaimer information, 2
Distilled water applications, 18
Draining, 37
Electrical connections, 24, 40
Electrical subpanel, 26
Electricals, 30
Expansion tank, 20
External piping sizing
considerations, 16
General information
Available options, 89
Models covered, 7
Necessary documents, 67
Standard features, 8
Heater contactor, 29
Heaters, 28
High-mobility piping
considerations, 18
Identifying controls and features,
2731
Communications, 31
Controller operation, 31
Identifying mechanical
controls and features, 27
31
Identifying mechanical controls
and features, 2731
Incomplete shipment, 13
Incorrect shipment, 13
Installation information, 1626
Cooling water connections,
20
Electrical connections, 24
Page 48
Index
External piping sizing
considerations, 16
High-mobility piping
considerations, 18
Location considerations, 16
Permanent piping
considerations, 17
Process approach
temperature
considerations, 16
Process water connections,
19
Process water
considerations, 18
System purge connections,
21
Location considerations, 16
Low pressure cutout switch,
28
Maintenance
Cleaning and storage, 43
Corrective maintenance, 38
40
Draining, 37
Electrical connections, 40
Heaters, 40
Motor overload, 41
Periodic checks, 38
Pressure switch, 41
Preventive maintenance, 37
Pumps and seals, 38
Safety devices, 41, 4043
Safety thermostat, 43
Solenoid valves, 40
Models covered, 7
Motorized modulating valves,
29
Necessary documents, 67
Options, 89
Periodic checks, 38
Permanent piping
considerations, 17
Pipe sizes for hp to 7 hp
units, 17
Pressure drops, 23
Pressure relief valve, 27
Pressure switch, 31
Preventive maintenance, 37
Process approach
temperature
considerations, 16
Process water connections, 19
Process water considerations,

18
Pump curves
50 Hz pump curves, 23
60 Hz pump curves, 23
Pump starter, 29
Pumps, 28
Pumps and seals, 38
Raw water treatment, 18
Returns, 13
Safety considerations, 3
Safety devices, 4043
Safety thermostat, 27
Sequence of operation, 34
Shipping damages, 12
Shipping information
Incomplete shipment, 13
Incorrect shipment, 13
Returns, 13
Shipping damages, 12
Uncrating, 14
Unpacking and inspection,
12
Shock stop, 29
Shutting down the unit, 35
Solenoid valves, 28
Specifications, 11
Standard features, 78
Starting the unit, 33
Startup and operation
Checking motor rotation
direction, 35
Sequence of operation, 34
Shutting down the unit, 35
Starting the unit, 33
Startup checklist, 32
Startup checklist, 32
Subpanel, 26
System purge connections, 21
TCU drawing, 10
TCU specifications, 11
TCU Upright drawing, 11
Thermocouple, 27
Thermostat, 27
To Process thermocouple, 27
Transformer, 29
Troubleshooting, 4547
Typical piping schematic, 22
Uncrating, 14
Unit drawing, 10, 11
Unpacking and inspection, 12
Water hammer arrestor, 29
Parts Department
Call toll-free 7am5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specifications, which will maximize your equipments performance
and efficiency. To assist in expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manual
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing
excellent customer service.
Service Department
Call toll-free 8am5pm CST [800] 423-3183 or call [262] 641-8610
Emergencies after 5pm CST, call [847] 439-5655
We have a qualified service department ready to help. Service contracts are available for most
products.
Sales Department
Call [262] 641-8610 MondayFriday, 8am5pm CST
Our products are sold by a worldwide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.
Contract Department
Call [262] 641-8610 MondayFriday, 8am5pm CST
Let us install your system. The Contract Department offers any or all of these services: project planning;
system packages including drawings; equipment, labor, and construction materials; and union or nonunion installations.
Sterling/Sterlco
2900 S. 160th Street
New Berlin, WI 53151
[262] 641-8610 Fax [262] 641-8653
Page 49

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Operation and Installation Manual

Part No. 682.88105.00

Bulletin No. SC1-610.8

Write down your unit serial number(s)

here for future reference

Royal Series Water Temperature Control Units

Royal Series Water Temperature Control Units

General Information ................................................6

Shipping Information .............................................12

Identifying Mechanical Controls and Features .............................. 27

Startup and Operation ...........................................33

Installation Location Considerations.............................................. 16

Identifying Controls and Features ........................27

Unpacking and Inspection............................................................. 12

Corrective Maintenance ................................................................ 39

Royal Series Water Temperature Control Units

Royal Series Water Temperature Control Units

Standard Royal Series Features

Compact, rugged cabinet with easy-access side panels

Cast-and-flange design to reduce connection points

Half- and full-heat automatic switching capability

Dual stage Incoloy immersion heater with IEC contactors

NEMA 12 electrical enclosure

Microprocessor controller with fuzzy logic; includes

Royal Series Water Temperature Control Units

Forward-facing liquid-filled To and From Process pressure

Independent high temperature safety thermostat

Non-fused lockable rotary disconnect

cooling solenoid valve on to 3 hp (0.56 to 2.24 kW)

EPDM/NI-Resist pump seal

Adjustable low supply water pressure switch; factory-set at

150 psig (1,034 kPa/10.3 bars) pressure relief valve

Choice of 230 or 460 operating voltages

water supply and drain connections; 1 process

Automatic vent sequence

3 (76 mm) casters

Operating range of 0F to 250F (-17C to 121C)

Controller with integral flow meter; with:

Royal Series Water Temperature Control Units

Remote set point and retransmission; 0-20 mA and 4-20

Remote controller enclosure

Heaters available in 12 kW, 18 kW, 24 kW, 36 kW, and 48

Closed-loop heat exchanger available in 3.7 sq. ft. (0.344 sq.

Quick Cool function

Auto system water purge (mold purge)

Hammer arrestor (water hammer shock stop)

Remote start/stop control

Rubber feet; available in lieu of casters

Non-ferrous brass construction

Slow-close cooling solenoid valves available in 1/2 x 9/16

Modulating valves available in 1/2 (CV = 0.4, 1.3, 2.2,

Two-zone stack rack with casters, common wiring and piping

300F (149C) operation; includes graphite-impregnated

Audible and visual general fault alarm

Electrical operation available in 208, 230, 460, and 575 volts,

UL/CUL-listed electrical subpanel

Royal Series Water Temperature Control Units

COOLING WATER OUT

THIS EQUI PMEN T CONTAI NS FLU ID, PIPI NG A ND CONNECTI ONS

5 . THI S EQUI PMENT MUST NO T BE USED W HIL E UNATTENDED.

ES TE EQUIPO CO NTI ENE FLUI DO, TUB ERIA Y CONEXIO NES Q UE

6 . VENT AND DRA IN PRO VISIO NS MUST NOT BE RESTRICTED.

5 . ESTE EQ UIPO NO DEBE S ER USA DO C UANDO NO HAY QUIEN